The modification of a thermally sprayed cemented carbide (WC-CrC-Ni) layer by friction stir processing (FSP) was studied. The cemented carbide layer was successfully modified using a sintered cemented carbide (WC-Co) tool. The defects in the cemented carbide layer disappeared and the hardness of the cemented carbide layer increased to ～2000 HV, which was about 1.5 times higher than that of the as-sprayed cemented carbide layer. Additionally, the cemented carbide layer was bonded to the SKD61 substrate by diffusion of the metallic elements and the distortion of the coating - substrate interface producing a mechanical interlocking effect.

The modification of a thermally sprayed cemented carbide (WC-CrC-Ni) layer by friction stir processing (FSP) was studied. The cemented carbide layer was successfully modified using a sintered cemented carbide (WC-Co) tool. The defects in the cemented carbide layer disappeared and the hardness of the cemented carbide layer increased to ～2000 HV, which was about 1.5 times higher than that of the as-sprayed cemented carbide layer. Additionally, the cemented carbide layer was bonded to the SKD61 substrate by diffusion of the metallic elements and the distortion of the coating - substrate interface producing a mechanical interlocking effect.